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Replacing 1991 Golf Cabrio Headlight Bulbs

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Hi Everyone! I just purchased a 91 Gold Clipper Cabrio and am really enjoying it! I would like to replace the headlight bulbs with some Philips H4 RacingVisions. Is there a how-to guide on here? I am NOT very mechanical at all, so the easier the better. Eventually, I would like to get new Hella headlamp covers, but all in good time :)

Thanks!


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'91 VW Clipper Cabby, 5 speed, 1.8 (Weber with manual choke). I have no idea what I'm doing, so please show mercy.

  2857C4E6-41B8-46FE-84E5-8275A978BAFA.jpegw300 790E3798-CF8E-4797-8FF6-DDA39B680915.jpeg

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First I would suggest that you relay your headlights so that your new bulbs get more current and higher voltage.

You can buy the relaying kits on ebay or make your own.  This is the first thing I would do.

https://www.amazon.com/2-Headlight-Headlamp-Ceramic-Socket-Harness/dp/B06XHSFLTZ/ref=sr_1_7?dchild=1&gclid=CjwKCAiA7939BRBMEiwA-hX5J3nwcXCYopfGgj_7gKR9l2wPm8b9nR1dvFSFseVhm5FaYnUJ5U-71hoCmQ4QAvD_BwE&hvadid=190526126392&hvdev=c&hvlocphy=9010813&hvnetw=g&hvqmt=e&hvrand=4286540173252062803&hvtargid=kwd-301705596938&hydadcr=7472_9322242&keywords=headlight+relay+kit&qid=1605898256&sr=8-7&tag=googhydr-20

https://www.ebay.co.uk/itm/1PC-Car-H4-Headlight-Lamp-Bulb-Relay-Wiring-Harness-Kit-Socket-Plug-Wire-12V-UK/293421903672?hash=item44514eef38:g:rygAAOSwSwleHCL6

How I did it, and there are 2 schematics one similar to the 2 relay on amazon, the second one at the bottom has 3 relays so all lamps and all filaments can operate at the same time.

https://www.volkswagenownersclub.com/threads/relaying-your-head-lights.32215/

This is one of the cheapest and best things you can do.  It shortens the run of wire from the Battery to the headlight, so you get more current and a higher voltage to the bulb it will be brighter.  As you use the original harness to operate the new relays, you reduce the current that is used through the headlight switch.

Open the hood.
On the upper corners of your grille are 2 plastic covers as circles at the corners of your grille that have to be removed, if they are gone, then remove the 2 screws one in each corner.


Screen Shot 2020-11-20 at 1.55.15 PM.png

Remove the screws on the front valance (2).

Carefully unclip it at the top, and then lower the grille and disconnect the 2 inner 5" lamps, remove rubber boot, , and remove the 2 wires Brown goes to ground, the other is power to the inner bulb.

Now that the Grille is off at the top, carefully tilt it at an angle and lift up, there are little hinge clips at the bottom edge of the grille holding it in at the bottom.

Mark the aluminum collar at the 12 o'clock position easier to put them back later.

Screen Shot 2020-11-20 at 1.54.18 PM.png

Remove the 3 screws that hold the 7" beams collars.
Once removed you can take the headlamp out and disconnect it from the socket.
 

What do Divorces, Great Coffee, and Car Electrics all have in common?

They all start with GOOD Grounds.

Where are my DIY Links?

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Thank you for this - much appreciated! I'll take a look! I hope I don't screw it up!

'91 VW Clipper Cabby, 5 speed, 1.8 (Weber with manual choke). I have no idea what I'm doing, so please show mercy.

  2857C4E6-41B8-46FE-84E5-8275A978BAFA.jpegw300 790E3798-CF8E-4797-8FF6-DDA39B680915.jpeg

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bsteph50 said

Thank you for this - much appreciated! I'll take a look! I hope I don't screw it up!

Just updated this with pics and links.

What do Divorces, Great Coffee, and Car Electrics all have in common?

They all start with GOOD Grounds.

Where are my DIY Links?

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Sweet!!! Even better!!!

'91 VW Clipper Cabby, 5 speed, 1.8 (Weber with manual choke). I have no idea what I'm doing, so please show mercy.

  2857C4E6-41B8-46FE-84E5-8275A978BAFA.jpegw300 790E3798-CF8E-4797-8FF6-DDA39B680915.jpeg

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Replacing 1991 Golf Cabrio Headlight Bulbs

I am considering doing this with my cabby as well. I have quad grille with H3 inner lights.

I see you have linked to some harnesses. But it doesn't look like like they include wiring for the inner lighting. Got some tips for that?

Cheers!


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Ah,  on the harness you have one relay for the low beams and one for The highs on the standard headlight.
For the Quad or inners, you have to extend a wire over to the 5" headlights Solder and heat shrink.  

Basically you will cut the wire going to your inners, the Colored wire not the brown, and then jumper it to the socket that the 7" uses on the high beam.

in my how do I do that's that is linked above, I have the how to make your own with good pictures of what you need to do to get the inners to work from the high beams main socket.


What do Divorces, Great Coffee, and Car Electrics all have in common?

They all start with GOOD Grounds.

Where are my DIY Links?

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Replacing 1991 Golf Cabrio Headlight Bulbs

Great! Thanks alot


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Just have a quick question for you Brian. I had a look at your "how to" when wiring.

And I saw this picture:

InkedDCP_7860_LI.jpg

And I wonder, is this a bracket for holding the connector for the inner lighting?
Do you have parts number, or know where I can get them?

Cheers!

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I think it is item 22, as it is in the bottom  of the etka a a bare part number, nothing no picture.  But looking up that part number 155971843C

lead me here to this link.
https://www.ebay.co.uk/itm/Genuine-VW-Bracket-NOS-VW-Golf-Cabriolet-Rabbit-Cabrio-155971843C-/143190568296

Kind of looks like 22.

What do Divorces, Great Coffee, and Car Electrics all have in common?

They all start with GOOD Grounds.

Where are my DIY Links?

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I took inspiration from Brians posts and went a bit OTT…
https://vwgolfmk1.org.uk/forum/index.php?page=topicview&type=findpost&id=1642961

My rebuild thread I will try and keep up to date: here

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